MIN-310 The Magnificent Seven Tools

MIN-310 Quality Management (Dvivedi- 4/13/2019
For limited Circulation)
The New Seven Q.C. Tools
MIN-310
Instructor – Dr. Akshay Dvivedi

2018-2019
This material is for classroom
4/13/2019
This material discussion
is for teaching andand teaching only
classroom discussion only
Need for New Seven Q.C. Tools
 Japanese felt that managers should not only

know the elementary statistical system but also
sophisticated techniques
 The practice of TQC not only requires numerical
data but also verbal data or verbal
communication, which may not be computable
 There should be suitable methods to process
these information with a view to arriving at a
complete plan This material is for teaching and
4/13/2019
This material is for teaching and

classroom discussion only 1
History of the New Seven QC Tools
 Committee of J.U.S.E.* - 1972

 Aim was to develop more QC techniques for
use by managerial level staff
 Work in conjunction with original Basic Seven
Tools
 New set of methods (N7) - 1977
*Japanese Union of Scientist and Engineers

4/13/2019
History of the New Seven QC Tools
 Developed to organize verbal data

diagrammatically.
 Basic 7 - tools effective for data
analysis, process control, and quality
improvement (numerical data)
 Used together increases TQM
effectiveness
4/13/2019

Basic Seven Q.C. Tools?
Flow Charts
 Run Charts
 Histograms
 Pareto Diagrams
 Cause and Effect Diagrams
 Scatter Diagrams

4/13/2019
Control Charts
What are the New Seven Q.C. Tools
Affinity Diagrams
 Relations Diagrams
 Tree Diagrams
 Matrix Diagrams
 Arrow Diagrams
 Process Decision Program Charts
 Matrix Data Analysis
4/13/2019

Relation Between New Seven Q.C. Tools

and Basic Seven Tools
FACTS
Data
Numerical Data Verbal Data

Define problem after Define problem before
collecting numerical data collecting numerical data
The Basic Seven Tools The Seven New Tools
•Analytical approach •Generate Ideas

Organize •Formulate plans
Information
4/13/2019
Affinity Diagrams
For Pinpointing the Problem in a Chaotic

Situation and Generating Solution Strategies
 Creative process used by a group to

gather and organize verbal data (ideas,
opinions, issues)

4/13/2019

Affinity Diagrams
 Organizes the data into groups based

on natural relationship
 Makes it feasible for further analysis
and to find a solution to the problem.

4/13/2019
Affinity Diagrams
Constructing an Affinity Diagram
Group Method Approach
 Select a topic
 Collect verbal data by brainstorming
 Discuss collected info until everyone
understands it thoroughly
 Write each item on separate data card
 Spread out all cards on table
4/13/2019

Affinity Diagrams
Constructing an Affinity Diagram

Group Method Approach (cont.)
 Move data cards into groups of similar

themes (natural affinity for each other)
 Create a title for each group
 Draw the affinity diagram
 Presents the results

4/13/2019
Affinity Diagrams
Completing an Affinity Diagram
Topic
Affinity Statement Affinity Statement Affinity Statement
Data Card Data Card Data Card Data Card Data Card Data Card
Data Card Data Card Data Card Data Card Data Card Data Card
Data Card Data Card
Affinity Statement
Data Card Data Card
Data Card

4/13/2019

Affinity Diagrams
Problems faced by surgeons
What are shortcomings that are overlooked in Operation Theaters?
Overloading Monotonous atmosphere Soiling of feet & floor
In adjustable length of Improper height of scrub Clustered

portions of table. station consumables in
operation theaters
Scrub solution Dangling O.T. lights with Lack of desired
dispensers are poor focus and support from
cumbersome illumination. supporting staff
Patients don’t Seating arrangements for Cumbersome
understand what surgeon surgery are either mechanical
says uncomfortable or mechanism of table
Incompatibility between tall surgeons unstable
Base of Operation table is very broad
and short assistants and vice versa.
Bulky lights causing Width of table is not alterable Lack of shower
mobility problems system
4/13/2019
Affinity Diagrams
Problems faced by surgical team & supporting staff
Monotonous atmosphere Lack of consumables
Overloading Soiling of feet & floor

Lack of job distribution,
i.e., job definition is
Irrational behavior of
No technical person is unclear
surgeon
available for routine Lack of cooperation from
maintenance of the floor staff
Poor quality
equipments
instrumentation
Lack of communication
Incompatibility between
Exposed to irradiation from surgeon about his
tall surgeons and short
requirements for a case
assistants and vice versa
Assisting from a distance with poor visibility & awkward position where as
surgeon expects perfect assistance
4/13/2019

Affinity Diagrams
Problems faced by attendants / visitors
Uncomfortable Negative thoughts Monotonous

waiting place atmosphere
I want to accompany Nauseating smell, Lack of information

my patient mysterious and frightening exchange at O.T.
environment entry
Lack of identification What is being done to my Lack of

by O.T. staff patient inside O.T. causes identification of O.T.
misery to me? staff

4/13/2019
Affinity Diagrams
Problems faced by patients.
Lack of privacy Lack of communication Pressure sores
Monotonous Lack of identification of Cold stretcher and

atmosphere surgeon/surgical team O.T. table when
patients are washed
up and are in thin
Flimsy arm support which is at low level from table O.T apparel
causes pain in arms

4/13/2019

Affinity Diagrams
Problems faced by O.T staff
Design/planning issues Problems in & around O.T. Table and seating
1. Clustered consumables in O.T. 9. Seating arrangements for surgery (stools) are either uncomfortable
2. Improper height of scrub or unstable
station 10. Dangling O.T. lights, due to loose ceiling mounts with poor focus
3. Lack of shower system and illumination.
4. Scrub solution dispensers are 11. Base of Operation table is very broad, resulting in back problems
cumbersome 12. Width of table is not alterable.
5. Poor quality instrumentation 13. Cumbersome mechanical mechanism of table.
6. Lack of consumables 14. Pressure sores
7. Exposed to irradiation 15. Bulky lights causing mobility problems
8. Lack of technical help 16.One has to assist from a distance with poor visibility & awkward
position where as surgeon expects perfect assistance
Personal or individual problems 17. In adjustable length of portions of table
22. Lack of desired support from 18. Cold stretcher and O.T. table when patients are washed up and are
supporting staff in thin O.T. apparel
23. Incompatibility between tall 19. Flimsy arm support at low level from table causes pain in arms
surgeons and short assistants 20. Soiling of floor
and vice versa 21. Soiling of feet
24. Identification problems Communication related problems
25. Unclear Job definition 28. Irrational behavior of surgeon
26 Overloading 29. Patients don’t understand what surgeon says
27. Monotonous atmosphere 30 Lack of communication from surgeon about his requirements for a
case
4/13/2019
Affinity Diagrams
Advantages of Affinity Diagrams
 Facilitates breakthrough thinking and

stimulate fresh ideas
 Permits the problem to be pinned down
accurately
 Ensures everyone clearly recognizes the
problem
 Incorporates opinions of entire group
4/13/2019

Affinity Diagrams
Advantages of Affinity Diagrams
 Fosters team spirit

 Raises everyone’s level of awareness
 Encourages the group into action

4/13/2019
Relations Diagrams
Relations Diagram, is a tool for finding

solution to problems that have complex
causal relationship.
 Resolves tangled issues by untying the logical

connection
 Allows for “Multi-directional” thinking rather
than linear thinking
 Also known as Interrelationship diagrams

4/13/2019

Relations Diagrams
Constructing a Relations Diagram

 Express the problem in form of “Why isn’t

something happening?”
 Each member lists 5 causes affecting problem
 Write each item on a card
 Discuss info collected until everyone

understands it thoroughly
4/13/2019
Relations Diagrams

 Move cards into similar groups

 Asking why, explore the cause-effect
relationships, and divide the cards into
primary, secondary and tertiary causes
 Connect all cards by these relationships

4/13/2019

Relations Diagrams
 Further discuss until all possible causes have

been identified
 Review whole diagram looking for
relationships among causes
 Connect all related groups
Next, complete the diagram

4/13/2019
Relations Diagrams
Litter Problem
First Iteration
4/13/2019

Relations Diagrams
Litter Problem
First Iteration
4/13/2019
Relations Diagrams
Litter Problem
First Iteration
4/13/2019

Relations Diagrams
Litter Problem
Completed Relationship Diagram

4/13/2019
Relations Diagrams
Litter Problem
Completed Relationship Diagram

4/13/2019

Relations Diagrams
Completing a Relations Diagram

Tertiary Tertiary
Cause Secondary Cause
Primary Cause Cause
Primary Cause Tertiary

Secondary Cause
Cause Why doesn’t
X happen? Secondary
Cause
Primary Cause Primary Cause

6th level
Secondary
Cause
Tertiary Cause
Cause Tertiary
Secondary
Cause
Cause 4th level
4th level 5th level
Cause Cause Cause
4/13/2019
Relations Diagrams
Advantages of Relations Diagrams
 Useful at planning stage for obtaining

perspective on overall situation
 Facilitates consensus among team
 Enables priorities to be identified accurately
 Makes the problem recognizable by clarifying
the relationships among causes

4/13/2019

Tree Diagrams
Tree Diagram is a technique for mapping out

full range of paths and tasks that need to be
done in order to achieve a primary goal and
related sub goals.
Such a diagram reveals in a simple way with

clarity not only the magnitude of the problem
but also helps to arrive at methods, which are
to be pursued to achieve the results.

4/13/2019
Tree Diagrams
For Systematically Pursuing the Best Strategies

for Attaining an Objective
 Develops a succession of strategies for

achieving objectives
 Reveals methods to achieve the results.
 Also known as Systematic diagrams or
Dendrograms

4/13/2019

Tree Diagrams
Constructing a Tree Diagram
 Write Relations Diagram topic (Objective card)
 Identify constraints on how objective can be achieved
 Discuss means of achieving objective (primary

means, first level strategy)
 Take each primary mean, write objective for

achieving it (secondary means)

4/13/2019
Tree Diagrams
Constructing an Tree Diagram
 Continue to expand to the fourth level

 Review each system of means in both directions
(from objective to means and means to objective)
 Add more cards if needed

 Connect all levels

4/13/2019

Tree Diagrams
Tree Diagram
4th means
3rd means 4th means

Secondary means
3rd means 4th means
Primary means 4th means
3rd means
4th means
3rd means
Secondary means
To 4th means
Accomplish 4th means
3rd means 4th means
Secondary means 3rd means 4th means
4th means
Primary means
3rd means 4th means
Constraints
Secondary means 3rd means 4th means
4/13/2019
Tree Diagrams
Key Question?

4/13/2019

Tree Diagrams
Completing a Tree Diagram

4/13/2019
Tree Diagrams
Advantages of Tree Diagrams
 Systematic and logical approach - less likely

that items are omitted
 Facilitates agreement among team

4/13/2019

Matrix Diagram
In the strategic quality planning process, we

typically see interrelated factors. Hence, a
change in one factor will often affect others.
Therefore, we must address trade-offs. We must

discover factor relationships critical to our
strategic plan as soon as possible, in order to
deal with them in a timely fashion.

4/13/2019
Matrix Diagram
The matrix diagram offers us a versatile,

graphical tool to facilitate both discovery and
trade-offs. The matrix diagram is designed to
facilitate the identification of relationships
between two or more sets of factors.

4/13/2019

Matrix Diagram
For Clarifying Problems by

“Thinking Multi-dimensionally”
 Consists of a two-dimensional array to

determine location and nature of problem
 Discovers key ideas by relationships
represented by the cells in matrix.

4/13/2019
Matrix Diagram
 Applied when:
interrelationship of the following need to be presented
 Effects & causes
 Objectives & methods
 People & functions
interrelationship need to be characterized
 Exists or does not exist
 Strong, medium, weak
 type

4/13/2019

Matrix Diagram
Constructing a Matrix Diagram
 Write final-level means from Tree diagram forming

vertical axis
 Write in Evaluation categories (efficacy, practicability,

and rank) on horizontal axis.
 Examine final-level means to identify who will

implement them
 Write names along horizontal axis

4/13/2019
Matrix Diagram
O O =1 O =4 Principal
O =2 O X =5 O Subsidiary
=3 X =6
Evaluation Responsibilities
Section/Plant QC circle
Section/Plant Manager
Remarks
Site QC circle
Practicability
supporter
Member
Efficacy
Leader
Rank
4th level means

from Tree diagram O O 1 O
4th level means
from Tree diagram O O 1 O Hold 4 times/month
4th level means
from Tree diagram O 4 O At every meeting
4th level means
from Tree diagram O 2 O
4th level means
from Tree diagram O X 5 O At least 3 times/year/person
4th level means
from Tree diagram O O 1 O O
4th level means
from Tree diagram 3 O
4th level means
from Tree diagram O 2 O
4th level means
from Tree diagram O O 1 O
4th level means
4/13/2019 from Tree diagram O O This1material is for teaching and O

Matrix Diagram
Constructing a Matrix Diagram (cont.)
 Label group of columns as “Responsibilities”

 Label right-hand end of horizontal axis as “Remarks”
 Examine each cell and insert the appropriate symbol:
Efficacy: O=good, =satisfactory, X=none
Practicability: O=good, =satisfactory, X=none

4/13/2019
Matrix Diagram
Constructing a Matrix Diagram (cont.)
 Determine score for each combination of symbols,

record in rank column
 Examine cells under Responsibility Columns, insert

double-circle for Principal and single-circle for
Subsidiary
 Fill out remarks column and record meanings of
symbol

4/13/2019

Matrix Diagram

4/13/2019
Matrix Diagram
Advantages of Matrix Diagrams
 Enable data or ideas based on extensive

experience
 Clarifies relationships among different
elements
 Makes overall structure of problem
immediately obvious

4/13/2019

Arrow Diagrams
For Working Out Optimal Schedules and
Controlling Them Effectively
 Shows relationships among tasks needed to

implement a plan
 Network technique using nodes for events
and arrows for activities
 Used in PERT (Program Evaluation and
Review Technique) and CPM (Critical Path
Method)
4/13/2019
Arrow Diagrams
Constructing an Arrow Diagram
 From strategies, select one (Objective of

Arrow Diagram)
 Identify constraints to Objective
 List all activities necessary to achieving
Objective
 Write all essential activities on separate
cards

4/13/2019

Arrow Diagrams
Constructing an Arrow Diagram (cont.)
 Organize cards in sequential order of activities

 Remove any duplicate activities
 Review order of activities, find sequence with
greatest amount of activities
 Arrange parallel activities

4/13/2019
Arrow Diagrams
Constructing an Arrow Diagram (cont.)
 Examine path, number nodes in sequence

from left to right
 Record names and other necessary
information

4/13/2019

Arrow Diagrams
Completing an Arrow Diagram
Strategy Constraints
4 12
1 2 3 5 9 10 13
Activity
6 8 11
7
4/13/2019
Arrow Diagrams
Terms in a NETWORK

Arrow Diagrams
Completing an Arrow Diagram
PRECEEDING SUCCESSOR
ACTIVITY
EVENT
Activity Time [T] Earliest Start [ES] EF = ES + T

4/13/2019 Latest Start [LS]
Latest Finish [LF]
Arrow Diagrams
• Earliest Start is earliest time an activity can start ESij = Max
(EFi)
• Earliest Finish is ESij plus the activity time EFij = ESij + tij
• Latest Start is latest time an activity can start without delaying
critical path time LSij = LFij - tij
• Latest Finish is the latest finish time LFij = Min (LSj)

4/13/2019

Arrow Diagrams
Advantages of Arrow Diagrams
 Allows overall task to viewed and potential

problems to be identified before work starts
 Leads to discovery of possible improvements
 Makes it easy to monitor progress of work

4/13/2019
Arrow Diagrams
Advantages of Arrow Diagrams
 Deals promptly with changes to plan

 Improves communication among team
 Promotes understanding and agreement

among group

4/13/2019

Process Decision Program Chart
The Process Decision Program Chart (PDPC) is a

very useful and powerful method to overcome a
problem or a goal to be achieved.
With the help of PDPC we can map out all the

conceivable events or contingencies that can occur in
the implementation stage and also find out feasible
counter measures to overcome these problems.

4/13/2019

For Producing the Desired Result from Many
Possible Outcomes
 Used to plan various contingencies
 Used for getting activities back on track
 Steers events in required direction if
unanticipated problems occur
 Finds feasible counter measures to overcome
problems

4/13/2019

Constructing a PDPC
 Select a highly effective, but difficult strategy from the
Tree diagram
 Decide on a goal (most desirable outcome)
 Identify existing situation (Starting point)
 Identify constraints of objective
 List activities to reach goal and potential problems

with each activity

4/13/2019

Constructing an PDPC (cont.)
 Review list. Add extra activities or problems not

thought of previously
 Prepare contingency plan for each step and review

what action is needed if step is not achieved
 Examine carefully to check for inconsistencies and all

important factors are included

4/13/2019

Constructing an PDPC (cont.)
 Examine to make sure all contingency plans are

adequate

4/13/2019
Completing a PDPC
Start
NO
NO NO
NO
YES YES NO NO
YES
NO
4/13/2019 GOAL

Completing a PDPC

4/13/2019

Advantages of PDPC’s
 Facilitates forecasting
 Uses past to anticipate contingencies
 Enables problems to pinpointed
 Illustrates how events will be directed to
successful conclusion
 Enables those involved to understand
decision-makers intentions
4/13/2019

Matrix Data Analysis
Principal Component Analysis
 Technique quantifies and arranges data

presented in Matrix
 Based solely on numerical data
 Finds indicators that differentiate and attempt
to clarify large amount of information

4/13/2019
Advantages of Principal Component Analysis
 Can be used in various fields (market

surveys, new product planning, process
analysis)
 Can be used when Matrix diagram does not
give sufficient information
 Useful as Prioritization Grid

4/13/2019

Constructing a Prioritization Grid
 Determine your goal, your alternatives, and criteria

for decision
 Place selection in order of importance

 Apply percentage weight to each option (all weights
should add up to 1)
 Sum individual ratings to establish overall ranking
(Divide by number of options for average ranking)

4/13/2019

Constructing a Prioritization Grid (cont.)
 Rank order each option with respect to criterion

(Average the rankings and apply a completed ranking)
 Multiply weight by associated rank in Matrix (in

example, 4 is best, 1 is worst)
 Result is Importance Score

 Add up Importance Scores for each option

4/13/2019

Constructing a Prioritization Grid (cont.)
 Rank order the alternatives according to importance
See completed the diagram

4/13/2019

Completing a Prioritization Grid
Criteria Customer Acceptance Strength Importance Option
(most important) Cost Reliability (least important) Sum Score Ranking
Options
Design A
Percentage weight .40 .30 .20 .10
Rank 4 3 3 1
Importance score 1.6 .90 .60 .10 3.2 1 (tie)
Design B
Rank 3 4 1 2
Importance score .90 1.6 .10 .40 3.0 2
Design C
Rank 1 2 4 3
Importance score .25 .50 1 .75 2.5 3
Design D
Percentage weight 0.3 .10 .20 .40
Rank 3 1 3 4
Importance score .90 .10 .60 1.6 3.2 1 (tie)
Sum of weights 1.25 1.05 .75 .95
Average weight .31 .26 .19 .24
4/13/2019Ranking
Criterion 1 2 discussion4 only 3
classroom


4/13/2019

4/13/2019

Summary
New Seven Q.C. Tools

4/13/2019
Summary
New Seven Q.C. Tools
Benefits of New Seven Q.C. Tools

1- Provide Training in Thinking
2- Raise People’s Problem Solving Confidence
3- Increase People’s Ability to Predict Future Events
Roles of New Seven Q.C. Tools

1- Express verbal data diagrammatically
2- Make information visible
3- Organize information intelligibly
4- Clarify overall picture and fine details
4/13/2019 5- Get This
more people involved
material is for teaching and

Thank You

4/13/2019


MIN-310 The Magnificent Seven Tools

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MIN-310 The Magnificent Seven Tools

Uploaded by

Copyright:

Available Formats

MIN-310 Quality Management (Dvivedi- 4/13/2019

For limited Circulation)

The New Seven Q.C. Tools

Instructor – Dr. Akshay Dvivedi

Need for New Seven Q.C. Tools

 Japanese felt that managers should not only

This material is for teaching and

History of the New Seven QC Tools

 Committee of J.U.S.E.* - 1972

 New set of methods (N7) - 1977

*Japanese Union of Scientist and Engineers

History of the New Seven QC Tools

 Developed to organize verbal data

This material is for teaching and

Basic Seven Q.C. Tools?

What are the New Seven Q.C. Tools

This material is for teaching and

Relation Between New Seven Q.C. Tools

Numerical Data Verbal Data

The Basic Seven Tools The Seven New Tools

•Analytical approach •Generate Ideas

For Pinpointing the Problem in a Chaotic

 Creative process used by a group to

This material is for teaching and

This material is for teaching and

 Organizes the data into groups based

This material is for teaching and

This material is for teaching and

Constructing an Affinity Diagram

 Move data cards into groups of similar

 Presents the results

Affinity Statement Affinity Statement Affinity Statement

Data Card Data Card

Data Card Data Card

This material is for teaching and

This material is for teaching and

In adjustable length of Improper height of scrub Clustered

What are shortcomings that are overlooked in Operation Theaters?

Monotonous atmosphere Lack of consumables

Overloading Soiling of feet & floor

This material is for teaching and

What are shortcomings that are overlooked in Operation Theaters?

Uncomfortable Negative thoughts Monotonous

I want to accompany Nauseating smell, Lack of information

Lack of identification What is being done to my Lack of

This material is for teaching and

What are shortcomings that are overlooked in Operation Theaters?

Lack of privacy Lack of communication Pressure sores

Monotonous Lack of identification of Cold stretcher and

This material is for teaching and

This material is for teaching and

Advantages of Affinity Diagrams

 Facilitates breakthrough thinking and

This material is for teaching and

Advantages of Affinity Diagrams

 Fosters team spirit

This material is for teaching and

Relations Diagram, is a tool for finding

 Resolves tangled issues by untying the logical

This material is for teaching and

This material is for teaching and

Constructing a Relations Diagram